Typical Applications for Heavy Gauge Thermoforming

Thermoforming is the broad term for a plastic production process that heats a two-dimensional rigid thermoplastic sheet and by way of vacuum and/or pressure, forms that sheet into a three-dimensional shape. Thin gauge and heavy gauge thermoforming are the two distinct categories of plastic thermoforming. Productive Plastics’ core competency is in cut-sheet heavy gauge thermoforming with sheet materials ranging from .060 to .500 inches thick.

Indoor and outdoor applications based upon specific material selection

Heavy Gauge Thermoforming Technology

The heavy gauge thermoforming technology involves feeding cut sheets of thermoplastic material into a machine that carries the sheets through one or more heating stations until the sheets reach the forming station for molding. Once the sheets have been molded, the completed part is emitted from the machine. At this point, secondary steps are necessary to complete the finished part through the use of routing, drilling, and secondary assembly via mechanical fasteners and adhesive or solvent bonding.

Productive Plastics’ Heavy Gauge Thermoforming Capabilities

A wide range of vacuum forming technical capabilities are available based on the equipment used, materials used, and desired product properties.

Productive Plastics uses state-of-the-art equipment, including the following machines:

60″ x 72″ single station vacuum, pressure and twin sheet former

48″ x 96″ single station vacuum, pressure and twin sheet former

48″ x 72″ four station rotary vacuum, pressure and twin sheet former

84″ x 108″ four station rotary vacuum, pressure and twin sheet former

All machines are capable of pressure, vacuum and twin-sheet forming. The choice of the heavy gauge thermoforming technology in work done by Productive Plastic is always guided by the engineering and product specifications of the customer and part. Pressure forming is utilized in more than half of the thermoforming jobs.

Materials Commonly Used in Heavy Gauge Thermoforming

ABS – There is a broad spectrum of resins used across a number of applications and can be formulated to meet UL flammability standards.

PC/ABS – This alloy delivers UL approval in addition to high impact performance.

HDPE – This is a cost effective material for industrial applications requiring high impact strength.

TPO – This high impact material delivers performance in cold and high heat applications.

HIPS – This low cost resin is used in many POP applications requiring excellent forming characteristics.

PVC/Acrylic – This resin is widely used in micro-processor based equipment housings and meets most stringent UL standards for flammability. It can be made in a wide range of colors and textures.

Terminology Note

Productive Plastics and the plastics industry typically use the terms “heavy gauge thermoforming” and “heavy gauge vacuum forming” interchangeably. A common misspelling is “heavy gage thermoforming.”